Process of preparing unsaturated acids and aldehydes

ABSTRACT

UNSATURATED ALDEHYDES AND CARBOXYLIC ACIDS AS ACROLEIN OR METHACROLEIN AND ACRYLIC ACID OR METHACRYLIC ACID ARE OBTAINED BY THE REACTION OF PROPYLENE OR ISOBUTYLENE WITH OXYGEN AT AN ELEVATED TEMPERATURE IN THE PRESENCE OF A CATALYST CONTAINING A MIXTURE OF MOLYBDENUM OXIDE, TELLURIUM OXIDE AND AN ALUMINUM PHOPHATE.

United States Patent U.S. Cl. 260-533 9 Claims ABSTRACT OF THE DISCLOSURE Unsaturated aldehydes and carboxylic acids as acrolein or methacrolein and acrylic acid or methacrylic acid are obtained by the reaction of propylene or isobutylene with oxygen at an elevated temperature in the presence of a catalyst containing a mixture of molybdenum oxide, tellurium oxide and an aluminum phophate.

CROSS-REFERENCE TO RELATED APPLICATION This is a continuation-in-part of my copending application Ser. No. 483,858, filed Aug. 30, 1965, now abandoned.

BACKGROUND OF THE INVENTION Numerous attempts have been made in the past to prepare products of higher oxidation state from hydrocarbons, especially from the normally gaseous hydrocarbons. However, all prior catalysts and procedures for oxidizing monoolefinic gaseous hydrocarbons to monoolefinically unsaturated aldehydes or monoolefinically unsaturated carboxylic acids with the same number of carbon atoms as the hydrocarbon having serious shortcomings. The catalysts either have a very short active life, or they convert only a portion of the hydrocarbon to desired end groups per pass; they oxidize the hydrocarbon excessively to form high proportions of carbon monoxide or carbon dioxide or both; they are not sufficiently selective, so that the hydrocarbon molecule is attacked at both the olefinic unsaturation and at a methyl group; or the oxidation of the olefin does not proceed beyond the aldehyde stage. Catalysts are desirable to provide a mixture of unsaturated aldehydes and unsaturated carboxylic acids.

SUMMARY OF THE INVENTION Mixtures of acrolein and acrylic acid or methacrolein and methacrylic acid are obtained in good yields by oxidation of propylene or isobutylene at elevated temperatures of about 300 C. to 550 C. in the presence of novel catalysts containing a mixture of molybdenum oxide, tellurium oxide and an aluminum phosphate in molar ratios of 100 M00 100 TeO and 10-100 of an aluminum phosphate. The catalysts can also be designated as with P being in the form of a phosphate wherein each P is attached to 3 or 4 oxygen atoms. Such catalysts will convert about 100 mol percent of propylene, for example, of which about 75% is acrolein and acrylic acid.

DETAILED DESCRIPTION The reactants The essential reactants are (1) propylene or isobutylene and (2) an oxygen containing gas, which can be pure oxygen, oxygen diluted with an inert gas, oxygen enriched air or air without additional oxygen. For reasons of economy, air is the preferred oxygen containing reactant.

For the purpose of this invention the hydrocarbons which are oxidized, propylene and/ or isobutylene, can be defined generically by the formula wherein the end products formed, acrolein and acrylic acid or methacrolein and methacrylic acid, result from the oxidation of only one methyl group on the hydrocarbon molecule While the terminal CH =C remains intact.

Stoichiometric ratios of oxygen to olefin for the puropse of this invention are 1.5 to 1. Slightly lower amounts of oxygen can be used at a sacrifice of yield. It is preferred, however, to use 33 to 66% excess oxygen. Larger excesses do not impair the yields of aldehyde and acids, but for practical considerations an excess much above would require extremely large equipment for a given production capacity particularly when the source of oxygen is air. 1.5 to 4 mols of oxygen per mol of hydrocarbon represents a useful range.

The addition of steam into the reactor along with the hydrocarbon and oxygen containing gas is desirable but not absolutely essential. The tfunction of steam is not clear, but it seems to reduce the amount of carbon monoxide and dioxide in the efiluent gases.

Other diluent gases can be used. Surprisingly, saturated hydrocarbons such as propane are rather inert under the reaction conditions. Nitrogen, argon, crypton or other known inert gases can be used as diluents if desired but are not preferred because of the added cost.

The catalyst and its preparation amount of a molybdenum salt, a tellurium salt and an aluminum salt in water. Add the requisite amount of phosphoric acid to the aluminum salt solution. Add the tellurium salt solution to the molybdenum salt solution and then add the aluminum saltphosphoric acid mixture to the molybdenumtellurium salt mixture. The catalyst is then dried and baked at 400 C. for about 16 hours.

Supported catalysts can be prepared by adding a dry support or an aqueous slurry thereof to the aqueous solution of catalyst or the aqueous catalyst ingredients can be added to the slurry of the support.

Alternatively, a slurry of the catalyst ingredients can be prepared in water, then dried and baked. For supported catalysts the aqueous slurry of the catalyst ingredients can be added to an aqueous suspension of the support or vice versa, and then dried and baked.

Another method is to blend the dry ingredients of the desired particle size and then mix them thoroughly. Thorough blending and uniform particle size is desired.

A specific example of the solution method is now set forth.

In this procedure the ingredients are precipitated on blending.

(a) Dissolve .96 g. of ammonium molybdate in ml. of distilled water.

(1)) Dissolve 31.922 g. TeO in 70 ml. of concentrated HC Add the tellurium salt solution to the ammonium molybdate solution. A precipitate forms.

(c) Dissolve 95.58 g. of AlCl .6H O in water and add 46.2 g. of 85% H PO Add this mixture slowly to the precipitated ammonium molybdate-Te mixture.

Dry on a steam bath and bake for 16 hours at 400 C. Thereafter, the catalyst is ground to the desired mesh size and sieved. For supported catalysts an aqueous slurry of the support can be added to the catalyst ingredients, or vice versa, prior to drying and baking.

A supported catalyst may be prepared by adding to (c) 240 grams of an aqueous colloidal dispersion of microspheroidal silica in a concentration of 30-35% SiO (Ludox H.S.). The silica may also be added to one of the individual ingredients or (c) added to the silica dispersion.

Among the suitable supports are silica, silica containing materials, such as diatomaceous earth, kieselguhr, silicon carbide, clay, aluminum oxides and even carbon, although the latter tends to be consumed during the reaction.

Catalysts with molar rotios of 100 Mo, l0-100 Te and 10-100 of an aluminum phosphate are used successfully for oxidizing the monoolefinic hydrocarbon to aldehyde and/or carboxylic acid. The catalyst contains chemically bound oxygen so that the generic formula can be written as M0O TeO AlPO or other aluminum phos- P m-mu- Reaction conditions The reaction can be carried out in either a fixed or fluidized catalyst bed.

The reaction temperature can range from about 300 to 450 C. for the oxidation of propylene but the preferred range is from about 350 C. to about 450 C. Below 350 C. the conversion per pass is lower and low temperature tends to produce more aldehyde than desired. Usually, a longer contact time is needed at lower temperatures to obtain the yields of desired products obtainable at higher temperatures. Above 425 C. in the propylene oxidation some of the desired end products appear to be oxidized to carbon oxides. This is much more apparent at 450 C. For isobutylene, oxidation temperatures of 350550 C. are desirable with the preferred range being 35 0-45 0 C.

The molar ratio of oxygen to propylene or isobutylene should be at least 2 to l for good conversion and yields. Some excess oxygen, 33 to 66 mol percent is even more desirable and is preferred. There is no critical upper limit as to the amount of oxygen, but when air is used as the oxygen containing gas it becomes apparent that too great an excess will require large reactors, pumping, compressing and other auxiliary equipment for any given amount of desired and product. It is therefore best to limit the amount of air to provide a 33 to 66% excess of oxygen. This range provides the largest proportion of acid, under given reaction conditions. Also, since care is needed to avoid an explosive mixture, the limiting of air aids in that direction.

The molar ratio of steam to propylene or isobutylene can range from 0 to about 5 to 7, but best results are obtained with molar ratios of about 3 to 5 per mol of olefin and for this reason are preferred.

The contact time can vary considerably in the range of about 2 to 70 seconds. Best results are obtained in a range of about 8 to 54 seconds and this range is preferred. Longer contact times usually favor the production of acid at any given temperature.

The particle size of catalyst for fixed bed operations used is from 10-18 mesh. As is known, for fixed beds, the size may be of a wider range particle size. For fluid bed systems the catalyst size should be from 80- 325 mesh (U.S. Sieve).

The reaction can be run at atmospheric pressure, in a partial vacuum or under induced pressure up to 50- 100 p.s.i. Atmospheric pressure is preferred for fixed bed systems and a pressure of 1 to 100 p.s.i. for fluid bed reactions. Operation at a pressure which is below the dew point of the unsaturated acid at the reaction temperature is advantageous.

The data in the examples show that wide variations in percentages of unsaturated acids and aldehydes can be obtained with a single catalyst, using fixed ratio of reactants but changing the temperature and/or contact time. Further variation is obtainable by controlling the other variables in the reaction including the catalyst compositions within the limits set forth herein.

The examples are intended to illustrate the invention but not to limit it.

The examples A series of runs was made in a fixed bed reactor of a high silica (Vycor) glass tube 12 inches long and 30 mm. outer diameter. The reactor had three inlets, one for air, one for steam and one for propylene. Three external electrically operated heating coils were wound on the reactor. One of the coils extended along the entire length of the reactor and each of the remaining coils extended only about one half the length of the reactor.

Outlet vapors were passed through a short water-cooled condenser. Uncondensed gases were passed through a gas chromatograph (Perkin-Elmer model 154D) and analyzed continuously. The liquid condensate was weighed and then analyzed for acrylic acid and acrolein in the gas chromatograph.

The reactor was filled to about 90% of its capacity with 170 ml. of a catalyst made by the solution method described above, using a ratio of 75 M00 25 TeO and 50 AlPO Empirically the catalyst is and the P is present as PO The catalyst was not supported and had a mesh size of 10-18 (U.S. Sieve).

Steam at a temperature of ZOO-250 C. was first passed into the reactor. Then propylene and air were separately fed into the stream of water vapor. This mixture then passed through a preheater and entered the reactor at about 200-250" C. The reactor was preheated to about 285 C. before the gas feed was begun.

The ratio of reactants was about 2.955 mols of oxygen and 4.36 mols of steam per mol of propylene. Cold contact time was 22.5 seconds.

The reaction temperature was varied as the reaction proceeded.

The table below summarizes the data obtained in these runs:

M01 M01 percent yield on percent propylene converted Temp., propylene C. converted .Aer. AA 2 1 Aer. =Aerolein. 2 AA =Acrylic acid.

The mol percent efliciency was essentially the same as the yields.

I claim:

1. A method for preparing a mixture of unsubstituted monoolefinic aldehydes and monoolefinic monocarboxylic acids by oxidation of a methyl group of a hydrogen selected from the group consisting of propylene and isobutylene comprising contacting said hydrocarbon and oxygen in a 7 molar ratio of about 1.5 to 4 mols of oxygen per mol of 5 6 sists essentially of 100 M 10-100 TeO and 10-100 8. A method of claim 6 wherein the catalyst is a sup- AlP0 and the temperature is from about 350 C. to ported catalyst on a silica-containing support. about 450 C. 9. A method of claim 6 wherein there is present up to 3. The method of claim 2 wherein the catalyst has a 7 mols of water vapor per mol of isobutylene. molar ratio of about 75 M00 25 TeO and 50 AlPO 4. A method of claim 2 wherein the catalyst is a sup- References Cited ported catalyst on a silica-containing support. UNITED STATES PATENTS 5. A method of claim 2 wherein there iS present up 3,396,189 8/1968 Eden 260 533XU to 7 05 Water Per PwPYlene- 3,192,259 6/1965 Felterly et a1 zeo-sssu 6. The method of claim 1 for preparing a mixture 10 of methacrolein and methacrylic acid wherein the hydro- LORMINE WEINBERGER, Primary Examiner carbon is isobutylene, the oxygen ratio is 1.5 to 3, the catalyst consists essentially of 100 M00 10-100 TeO Asslstant Exammer and 10-100 AlPO and the temperature is from about 350 C. to about 450 C.

7. The method of claim 6 wherein the catalyst has a 252437; 260--604 molar ratio of about 75 M00 TeO and A1PO UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,57 57 Dated April 27, 1971 lnvent fil JAMAL S. EDEN It: is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3, line 25, "TeO should read --Te0 Column 4, line 64, Claim 1, "hydrogen" should read --hydroc In "References Cited" "Felterly should read --Fetterly-- Signed and sealed this 11th day of January 1972.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOTTSCHALK Attosting Officer Acting Commissioner of Patent 

